Update on the IBL vacuum flex transfer lines Claudio Bortolin, Carolina Deluca, Piotr Gach George Glonti, Jan Godlewski, Abdel Laassiri, Markus Lippert, Sylvain Nichilo, Martijn van Overbeek, Bart Verlaat, Sven Vogt Pixel week- 21st May 2014

Flex lines From S5 to IDEP Side A Side C ≈11m long

Status updated to 11th March presented during the review The program Optimize the design of the components ✔ Purchase the components: flex hoses, Swagelok fittings, vacuum parts ✔ Contact the welders and the mechanical technicians for production ✔ Purchase the orbital welding heads ✔ Pre-agreement with EN-MME for X-Rays checks schedule and availability ✔ Delivery of the purchased components: partially delivered Flex line parts production and assembly: work in progress Orbital welding and X-Rays: between week 12 and 15 Status updated to 11th March presented during the review Flex lines leak tests: week 15 and 16

General schedule Materials and components ordered on February 2014 Last design topic (brazing of capillaries) solved on 17th March The welding program was agreed with the PH-DT gas group responsible on 19th March Between weeks 13 and 16 we assembled, checked and tested 16 flex lines (14 lines + 2 spares)

Rotatable connector

Manufacturing of the parts Rotatable connector: machining and orbital welding carried out at MPI (Munich) Nut Gasket Sealing glands Profilometer measurements made by G. Romagnoli (PH-DT) at the EPFL (Lausanne) Pressure tests at 160 bars and Helium leak test were successful The rotatable connector can be completely disassembled to replace any possible damaged part

Flex concentric transfer line

Capillaries production Capillaries brazing parameters optimized and checked with a destructive test Brazing made by: Agostino Vacca (EN-MME) Metallography check result: “No lack of brazing could be observed. No overflown filler could be observed in the pipe.” Alexandre Gerardin (EN-MME) - 17th March

Welding quality verified Welding parameters optimized by Abdel L., Sylvain N. and Martijn van O., checked with ND or D tests for diameters: 3 mm, 4 mm, ¼”, 14 mm and 17.2 mm Capillary brazing: Pressure and leak tested The welding program parameters were archived for possible future productions

X-Rays check took place on Wed 2nd April Week 14 Flex lines assembly started according to the suggested sequence: 4 mm (Det) X-Rays check took place on Wed 2nd April

Week 14 17.2 mm (Det)

Capillaries insertion and ¼” connector welding

Each line may affect 7% of IBL We carried out about 200 orbital welding and 64 welds were qualified with X-rays. Acceptance criteria: EN1435 (Class B EN 25817) X-rays applied to: 1) welding test samples 2) all pressurized pipes connections Results: 16 lines with 100% welding conformities

Pressure test Helium Pressure test: we pressurized the liquid and gas pipes and looked for any leak with vacuum hoses connected to a leak detector Caps Helium Bottle Leak rates measured: 8x10-9 to 2x10-8 mbar l/s Helium leak detector

Connectivity table E-breakers Table n. 2 E-breakers Table n. 1 Flex line # Splitter box location (Clock wise) Flex line production ID To manifold location (From USA15 to UX15) Stave # Flow E-breaker N. A1 4 1 12 Vapor 195 C1 10 8 Liquid 187   13 139 85 A2 5 2 14 189 C2 3 11 9 135 133 153 A3 6 141 C3 95 103 105 A4 7 101 C4 97 51 93 A5 47 C5 83 167 91 A6 183 C6 15 77 203 81 A7 181 C7 16 45 171 19 E-breakers Table n. 2 E-breakers Table n. 1

Very good correlations between Flow and Dp Flow test results Nominal flow region Very good correlations between Flow and Dp

We are ready to install the flex lines in UX15 Summary We are ready to install the flex lines in UX15 Many people contributed to the successful construction and assembly of the flex lines for the IBL: Abdel Laassiri (PH-DT), Roberto Guida (PH-DT), Frederic Merlet (PH-DT), Sylvain Nichilo (EN-CV-DC), Olivier Crespo-Lopez (EN-CV-DC), Martijn van Overbeek (Nikhef) Miguel Gil Costa (EN-MME), Agostino Vacca (EN-MME), Thierry Callamand (EN-MME), Alexandre Porret (EN-MME), Aline-Marie Piguiet (EN-MME) and Alexandre Gerardin (EN-MME). I would like to particularly thank the PH-DT gas group, lead by Roberto Guida, for their support and effort during the production phase